The frictional partners of needle and sinker continuously endure high-speed movement and need a special lubricant to avoid friction and wear.
- Needle and sinkers constitute a major portion of the regularly replaced spares of the knitting machine. Life of the needle and sinker is critical to keep production and operational costs down. In order to reduce wear and increase needle life, the lubricating oil should be able to form a thin yet strong film between the narrow clearances of the sliding contact.
- Maximum wear due to friction occurs during the machine start up and shut down, considered as emergency run phase. Additives used in the formulation should help reduce co-efficient of friction in order to provide emergency lubrication during emergency runs
- Operating temperatures of around 75 °C is a standard norm in modern machines owing to high operating speeds and smaller clearances. Lubricating oils should not form any residues under these operating temperatures
- The centralized pump within the circular knitting machine is a precision equipment. Metered dosage of knitting oil in small quantities is pumped along the diameter of the cylinder. The knitting oil should not react with sensitive rubber sealing and plastic tubes in the system.
- Modern knitting machines are expensive and typically have a high quality paint finish. The aesthetic look of the machine indicates good care and maintenance practice. The knitting oil should remain inert and not react with paint or other machine coating
- Due to the location and arrangement of friction partners, traces of lubricating oil can splash onto the knitted fabric. However, these oil stains should be easily washable and not impact the dyeing process
BECHEM’s Range of Knitting Oils
BECHEM Staroil KNT Series
High-performance range of knitting oils for longer needle and lubrication life
- High-quality : Quality of base oil used directly impact the lubricating properties and lifetime performance of the oil. BECHEM’s Staroil KNT range of knitting oils are made from ultra-refined mineral base oils which provide best-in-class lubrication performance
- Ready for emergency lubrication : The special additive package in Staroil KNT’s range for wear protection increases productive life of needle and sinkers. The additives help in reducing friction during the start up and shut down phase which experience metal to metal contact
- Longer service life: Staroil KNT range have higher flash points and lower volatile loss. This also ensures lower consumption per machine per day. The special oils have superior oxidation stability and ensures minimum residue formation even after extended usage.
- No residues: Staroil KNT range of knitting oils do not form harmful residues when operating in highspeeds or high temperatures
- Resembling clear water, the additives in Staroil range are uniformly dispersed with no settlement of additives even after prolonged storage
- Leaves no stains: The special knitting oil has excellent scourability and any stains formed during operation can be easily washed using regular wetting agents
- Non-reactive: The unique formulation ensures that it does not react with machine paint or coating and resists corrosion. Compatible with electronic actuators, seals and plastic components. Also, mostly odourless and retains this characteristic even over extended usage
|Product||Base Oil||Flash point [°C]||Viscosity [mm2/S] at 40 °C||Send Your Queries|
|BECHEM Staroil KNT 32||Mineral Oil||Min 180||28.2-35.2|
|Product||Base Oil||Flash point [°C]||Viscosity [mm2/S] at 40 °C||Send Your Queries|
|BECHEM Staroil KNT 22||Mineral Oil||Min 170||19.8 – 24.2|
Frequently Asked Questions
Short bytes for queries on lubricants that always bothered you
Keeping a tab on oil health through oil analysis is a great proactive practice. It helps to check for contaminants and machine wear. Abnormal analysis result indicates potential danger in the system. Oil analysis helps in identifying root cause and take corrective measures immediately. Issues such as metal wear, broken seals, improper filtration pose greater threat to machine and can lead to extended and expensive downtime.
Regular oil analysis enables finding the right lubricating interval and increases the life of equipment. It also enhances productivity by reducing unplanned downtime resulting in smoother business operations.
Environment in which the lubricant is stored plays a crucial role in lubricant performance. Lubricants stored for long under extreme environmental conditions such as high temperatures, higher temperature variations, severe humidity and corrosive environments can affect the lubricant performance based on the product category.
Oils stored improperly beyond storage life established by the supplier, can have issues such as oxidation, sedimentation build up and moisture absorption. For greases, oil separation from the grease would be the primary concern.
Ambient temperature, clean and dry atmosphere can ensure maximum storage life of a lubricant. A consultation with the lubricant manufacturer on the shelf life of the lubricant is recommended to ensure quality.
Emulsifiers help in increasing solubility of the cutting oil in water by breaking down the oil into smaller globules and thereby maintaining a stable and uniform emulsion. A stable emulsion provides longer tank life and also ensures lower carry over loss resulting in minimum top ups.
The basic function of a cutting fluid is to provide adequate lubrication to the tool and work piece friction zone as well as remove heat generated by cooling the deformation area. Some additional properties that are desired in the cutting fluid are,
- Ability to rinse away the metal debris from the friction zone
- Provide adequate protection against corrosion to the machine and work piece
- Compatible to machine paint and ensure stain free machines
- Easy to handle and comply to safety and environmental regulations
Intense amount of heat is generated between the grinding wheel and work piece due to friction and cutting process. Uncontrolled heat can lead to structural damage of the work piece and increase in wear rate of the wheel. Fine dust and metal debris are continuously generated and needs to be cleared out from the wheel, work piece interface. The cutting fluid for Grinding process should possess the right amount of lubricity and cooling property to reduce friction and manage temperature rise. Additionally the cutting fluid should also possess the right amount of detergency and flushing property to clear the fine machined debris.
With a higher dosage of lubricity to reduce friction and temperature rise, the coolant should also contain EP additives that can protect the tool by forming a thin layer between the tool and work piece. Additionally, the cutting fluid should possess the right amount of flushing property to clear the machined swarf from the machined area
Ideally, de mineralized (DM) water with neutral pH of 7 and hardness less than 50 ppm is recommended. The chloride level should be less than 25 ppm with no bacterial and fungal presence. Usage of hard water leads to increased conductivity, hence poor rust protection and lower sump life.
‘Oil into water’ or ‘oil in last (OIL)’ is a recommended practice for better solubility of the coolant in water. Water in oil would result in large size oil globules with the oil loving ‘oleopphilic’ ions of the emulsifier being ineffective. This would lead to a unstable oil water emulsion.
- Keep a regular check on the concentration of the emulsion, maintain recommended concentration
- Remove any tramp oil from the coolant tank thoroughly
- Measure pH regularly
- Avoid all sorts of dust near the tank, remove the machined debris from the tank regularly.
- Follow the prescribed procedure while changing the coolant.
Including the effectiveness of ‘cutting fluid’, tool life is impacted by a host of other parameters including cutting speed, feed rate, depth of cut, tool and work material, nature of cut and machine rigidity. Cutting fluids with high amount of EP additives would insulate the tool from frictional wear and ensure longer life. Studies have shown that with all other parameters remaining the same, cutting fluids with good EP properties can increase tool life by 20 to 40%.
Aluminum alloys which contain Copper and Zinc as alloying elements are susceptible to chemical reaction (black stains) with cutting fluids that contain Amines as ingredient. For machining such Aluminum alloys, amine free cutting fluids are recommended
Colour change of the emulsion is notable during machining of Cast Iron with the Fe ions dissolving with the emulsion. However with all other parameters such as pH, conductivity, concentration and microbial behavior remaining within the specified limits, colour change does not impact performance of the emulsion.
Operators handling components with bare hands and in constant touch with the emulsion could feel irritation and itchiness or develop rashes as well. As sensitivity of the skin is subjective, operators need to handle machined components with proper gloves and other protective gear with the objective of avoiding direct contact with the emulsion. Barrier creams could also be considered where direct contact is unavoidable.
Ensuring a stable emulsion with regular check on pH levels and microbial growth by removing chips, swarf and tramp oil from the tank will also help in reducing possibilities of such concerns. Encourage operators to maintain good personal hygiene, recommend regular laundry of their work dress, avoiding wet rags into pockets, usage of mild soaps etc.